Today's solar cell production plants are faced with the pressure to continuously improve production efficiency and improve the efficiency of their products. In addition, the sharp changes in the prices of raw materials have also made it imperative. One of the main problems affecting production efficiency and product efficiency improvement is frequent and recurring pollution in the production environment. If the surface of the material is contaminated before the coating, printing or lamination process, the production efficiency will be seriously affected.
This article will focus on the impact of pollution; the main sources of pollution and the problems that may arise; and suggest a viable solution to reduce pollution problems.
How pollution affects the production of solar modules depends on which module of solar modules is produced. There are three types of module production:
The first generation of solar cells – silicon wafers – dust and dirt can affect the screen printing process, causing many problems like 'staging phenomenon', open circuit and short circuit. Volatilization and rapid expansion of contaminants in tin solder joints will result in miss and dry soldering. The solar cell is then packaged in an EVA film. If there is dust or dirt particles between the film and the battery, the end product will work less efficiently because it blocks sunlight. Even small polluted particles that are invisible to the naked eye, because of the 'tent effect', can produce a 'fisheye' on the surface of the recompressed surface, which can produce visual defects. These are all manufacturers should try to avoid.
The second generation of solar cells – vacuum alloys – is more efficient, but the surface of the substrate must be very clear before entering the deposition process. If contaminated particles appear in the wiring circuit, the same problems as the first generation process will occur, such as 'fisheye' and 'tombstone'. Similarly, if optimal battery efficiency is to be achieved, the glass or film surface must be cleaned during the packaging phase.
The third generation of solar cells utilizes screen printing technology similar to that used in the electronics industry. Usually such batteries are not as efficient as the first and second generations, so it is important not to reduce their efficiency because of contaminants. Therefore, the substrate and stencil must be thoroughly cleaned before each printing step. Substrates typically used for screen printing are plastic materials or metal foils. These substrates that are applied prior to coating or deposition are directly from the manufacturer and often carry contaminating residues. For example, plastic films are generally cut to different sizes according to customer requirements, and debris is likely to remain on the surface of the material. Electrostatic attraction of dust is also a serious problem.
Pollution is not just causing problems in the production process. If the contaminant is a conductive material that can cause corrosion of the finished product, it may only be discovered later in the product when it is stored in the warehouse. So what can be done to minimize the impact of solar cell production due to pollution? Many manufacturers draw on technology that has been proven by the semiconductor industry – contact cleaning technology.
Contact cleaning equipment can remove loose dirt particles as small as 1 micron on the surface of substrates such as silicon wafers, glass or EVA films without damaging the substrate surface. Teknek, a global leader in contact cleaning equipment, uses its special rubber rollers to remove contaminating particles from the surface of the substrate and transfer them to sticky rolls for final processing and analysis. Teknek's latest Nanocleen technology even removes particles as small as nanometers. The use of contact cleaners in every process where material surface contamination can occur can significantly increase production efficiency and solar cell efficiency. Compared with other cleaning methods such as non-contact vacuuming or blowing technology, contact cleaning has proven to be the most efficient surface because it is difficult to effectively break through the air boundary layer on the surface of the substrate. Dust removal, cleaning methods.
in conclusion
As the price of raw materials continues to increase, solar cell manufacturers must find ways to improve their production efficiency and reduce waste. Contaminants have an important impact on production efficiency and the efficiency of the solar cell itself. Contact cleaning technology provides an optimal alternative solution for increasing production and battery efficiency.
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